Building System for Forming a Wooden Panel into a Powder Coated Wall Structure

ABSTRACT

A method of assembling a powder coated wall frame supporting a wooden panel therein, by: (1) powder coating various metal members; (2) connecting top and side metal members together to form a frame having an open bottom; (3) inserting a wooden panel into the open bottom of the frame; and then (4) connecting a bottom metal member onto the side members, thereby sealing the wooden panel within the metal frame structure.

TECHNICAL FIELD

The present invention relates to systems for building barn walls andanimal stalls and pens.

BACKGROUND OF THE INVENTION

Existing building wall systems for barns and animal stalls typically usegalvanized steel members that are welded together. This has itsdisadvantages, especially when it is desired to have a portion of thewall system incorporate a wooden panel. Basically, the problem is thatthe wooden panel needs to be enclosed within the wall frame prior towelding the various frame pieces together. It is difficult to weld metalin close proximity to wood. Therefore, it is necessary to shield thewood from the heat of the welding (while welding in very close proximityto the wood).

It would instead be desirable to provide a strong metal wall system thatincorporates a wooden panel yet does not require welding around thewooden piece(s) during assembly. In addition, it would also be desirableto provide a wall frame that has metal members that are powder coated(since powder coated metals are more resistant to scratching and alsoretain paint longer). Unfortunately, it is not possible to weld togetherpowder coated metals. The present invention provides a solution to theabove problems by providing a wall frame that has powder coated metalmembers and a wooden panel which are held together without any welding.This results in a strong aesthetically appealing wall structure that issafe and easy to assemble.

SUMMARY OF THE INVENTION

The present invention provides a powder coated metal wall framestructure that is designed such that it can receive a wooden paneltherein. The various metal parts are bolted together which is veryadvantageous when working with a combined wood and metal structure. Mostimportantly, it is not necessary that any metal parts be weldedtogether. This avoids the problem of having to shield the wooden panelfrom the heat of welding. Secondly, the metal wall frame structure ispowder coated. This makes the metal structure more resistant toscratching and able to retain paint longer. Specifically, the metalstructure is preferably bolted together (which is advantageous since itis not possible to weld powder coated metal pieces together). Thus, thepresent metal frame system avoids the need for any welding equipment atall. Third, the present metal frame can be assembled quickly and easily,such that the wooden panel itself can be quickly slipped into the wallframe during assembly. Thus, a further advantage is that the woodenpanel can be inserted as a whole into the frame (as opposed to beinginserted into the wall frame in sections, although the present inventioncovers both approaches).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of the present wall structure(showing insertion of the wooden panels).

FIG. 2 is an assembled perspective view of the present wall structure(after the wooden panels have been installed).

FIG. 3 is a front elevation view of the present wall structure (with thecentral door and wooden panels removed for illustration purposes).

FIG. 4 is a view taken along line 4-4 in FIG. 3 (i.e.: looking straightdown).

FIG. 5 is a view taken along line 5-5 in FIG. 3 (i.e.: lookinghorizontally to the left).

FIG. 6 is a view taken along line 6-6 in FIG. 3 (i.e.: lookinghorizontally to the left).

FIGS. 7A and 7B are enlarged front and side views of a portion of thestructure of FIG. 3, showing the connection between the bottom and leftside members.

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1 to 7B all show various aspects of the structure of the presentinvention. The present invention encompasses both a metal wall structurethat encloses a wooden panel therein, and a method of assembling thewall structure so as to enclose the wooden panel therein.

FIGS. 1 to 3 show the wall structure as a three part system, with thetwo side portions each having a lower wooden panel and an upper barredwindow section. In FIGS. 1 and 2, the center portion also has a lowerwooden panel and an upper barred window section, however, this centerportion is a hinged door with a portion of the upper barred window beingleft open for a horse to stick their head through. It is to beunderstood that the present invention encompasses versions with orwithout this center doorway. It is also to be understood that thepresent invention also encompasses versions with a wooden panel thatextends partially or fully between the top and bottom members. Invarious embodiments, the top portion may be made of window bars, or thetop portion may be left open. In addition, the top and bottom portionsmay be made of one or more wooden panel sections. Thus, the presentinvention will be described as the portion of the wall structurecovering any one of the “thirds” shown in FIGS. 1 to 3.

As such, the present invention comprises a variety of different metalmembers, as follows: top member 10; bottom member 20; left side member30; and right side member 40. Members 10, 20, 30 and 40 are all made ofsteel that has been powder coated. As typically, understood, powdercoating typically involves applying a thermoplastic or thermoset polymerelectrostatically and then heat curing the thermoplastic or thermosetpolymer.

A plurality of channel members are also included, being: top channelmember 15; bottom channel member 25; left side channel member 35; andright side channel member 45. Channel members 15, 25, 35 and 45 are allpowder coated as well. As can be seen in FIGS. 4, 5 and 6, channelmembers 15, 25, 35 and 45 are all dimensioned with a C-shaped crosssection (so as to support both the front and back edges of the woodenpanel that is inserted into the wall structure).

As will be shown, the present invention is assembled as follows. First,a metal frame structure (having an open bottom end) is assembled. Next,one or more wooden panel sections may be slid into the open bottom endof the metal frame. (FIGS. 1 and 2 show a plurality of wooden sectionsinserted one after another, but it is to be understood that one singlewooden panel section can be used instead). Finally, the bottom metalmember is attached to the frame, sealing the wooden panel within themetal frame. The wooden panel is held in position by the four channelmembers (15, 25, 35, and 45). Specifically, left channel member 25 isconnected to left side member 20. Right channel member 45 is connectedto right side member 40. Bottom channel member 25 is connected to bottommember 20. Top channel member 15 spans horizontally between the left andright side members 30 and 40 mid way up along members 30 and 40, asshown. Top member 10 is connected to the top ends of the left and rightside members 30 and 40, respectively. Any or all of these connectionscan be done by bolting the members together.

Next, wooden panel sections 50A, 50B, 50C . . . 50I are slid upwards andreceived within the left, right, top and bottom channel members 15, 25,35, and 45 such that the top channel member 15 supports the top end offull wooden panel 50, left channel member 30 supports the left side ofwooden panel 50, the right channel member 40 supports the right side ofwooden panel 40. Specifically, wooden panel 50 (or its componentsections 50A, 50B, 50C, . . . etc.) are simply slipped up betweenchannel members 35 and 45 until its top end reaches (and slips into)channel member 15. Each of the left, right, top and bottom channelmembers 15, 25, 35 and 45 support the front and back of wooden panel 50.Then, bottom member 20 is connected to bottom ends of the left and rightside members 30 and 40, enclosing wooden frame 50. FIG. 7A illustrates aclose up front view of the bolted connection of members 30, 35, 20 and25. FIG. 7B illustrates a corresponding side view. In various optionalembodiments of the invention, the top portion of the wall structure(between top member 10 and top channel member 15) may be barred window(with vertical, tubular metal bard 60 spanning between top member 10 andtop channel member 15). In other optional embodiments, a moveable windowframe 70 may be positioned between top member 10 and top channel member15. Window frame 70 may be hinged to open or close. As can also be seen,the top portion of the wall structure can optionally comprise a fullhinged door 80, with an open portion 85 through which a horse may puttheir head.

It is to be understood that the present invention encompasses one woodenpanel 50, or any number of component wooden panels 50A, 50B, 50C . . .etc. that are simply slipped one by one up into the open frame ofmembers 10, 30 and 40 as the device is assembled.

1. A method of assembling a powder coated wall frame supporting a wooden panel therein, comprising: powder coating a top member, a bottom member, a left side member, a right side member, a top channel member, a bottom channel member, a left channel member and a right channel member; connecting the top member to top ends of the left and right side members; connecting the left channel member to the left side member; connecting the right channel member to the right side member; connecting the bottom channel member to the bottom member; connecting the top channel member to the left and right side members, wherein the top channel member spans horizontally between the left and right members mid way along the left and right members, thereby forming a frame having an open bottom; inserting a wooden panel into a open bottom of the frame such that the top channel member supports the top end of the wooden panel, the left channel member supports the left side of the wooden panel, and the right channel member supports the right side of the wooden panel; and then connecting the bottom member to the left and right side members, thereby enclosing the wooden panel within the frame, wherein the bottom channel member supports the bottom of the wooden panel.
 2. The method of claim 1, wherein the powder coating comprises applying a thermoplastic or thermoset polymer electrostatically and then heat curing the thermoplastic or thermoset polymer.
 3. The method of claim 1, wherein the connecting steps comprising: bolting the left and right side members to the top member bolting the left and right channel members to the left and right side members; bolting the top channel member to the left and right side members: bolting the bottom channel member to the bottom member; and bolting the bottom member to the left and right side members.
 4. The method of claim 1, further comprising: connecting parallel members between the top member and the top channel member.
 5. The method of claim 4, wherein the parallel members are tubular and are spaced apart from one another.
 6. The method of claim 1, further comprising: connecting a window frame between the top member and the top channel member.
 7. A powder coated wall frame structure supporting a wooden panel therein, comprising: a powder coated top member; a powder coated bottom member; a powder coated left side member; a powder coated right side member; a powder coated top channel member; a powder coated bottom channel member; a powder coated left channel member; a powder coated right channel member; and a wooden panel, wherein: the powder coated left channel member is connected to the powder coated left side member; the powder coated right channel member is connected to the powder coated right side member; the powder coated bottom channel member is connected to the powder coated bottom member; the powder coated top channel member spans horizontally between the left and right side members mid way along the left and right side members; the powder coated top member is connected to top ends of the left and right side members; the powder coated bottom member is connected to bottom ends of the left and right side members; and wherein the wooden panel is received within the left, right, top and bottom channel members such that the top channel member supports the top end of the wooden panel, the left channel member supports the left side of the wooden panel, and the right channel member supports the right side of the wooden panel.
 8. The structure of claim 7, wherein each of the left, right, top and bottom channel members support front and back sides of the wooden panel.
 9. The structure of claim 7, further comprising: parallel members connected between the top member and the top channel member.
 10. The structure of claim 9, wherein the parallel members are tubular and are spaced apart from one another.
 11. The structure of claim 7, further comprising: a window frame positioned between the top member and the top channel member.
 12. The structure of claim 11, wherein the window frame is hinged to open or close.
 13. The structure of claim 7, wherein all of the members are made of steel.
 14. The structure of claim 7, wherein all of the members are powder coated by a thermoplastic or thermoset polymer.
 15. The structure of claim 7 wherein the wooden panel is a single piece of wood.
 16. The structure of claim 7 wherein the wooden panel is a plurality of wood sections. 